Time is money in the production business and the more you waste, the more you lose. The Single-Minute-Exchange of Die (SMED) methodology may allow you to successfully implement a lean production process in your injection molding business, and when combined with a progressive mold maintenance program, allow you to reduce the time needed for changeovers.
Why Lean?
Lean manufacturing aims to eliminate unnecessary waste during production, and uncovering ways that will add value by eliminating or decreasing other processes or variables than can adversely effect production.
With the rising cost of transportation and raw materials, it has become increasingly important for injection molders to produce a wide variety of products. With that product expansion, the need for efficiencies and cost reductions has generated a lot of interest in the lean method.
Potential Problems in High Variety Production
Lengthy and difficult set up procedures.
Expensive, high-tech machines are required to increase production capacity and flexibility.
Waste arises out difficult changeovers, lack of adequate maintenance or equipment not being ready when needed.
SMED (Single-Minute-Exchange of Die and Maintenance
Globalization and Just-In-Time models have increased the need for production of smaller lots on a more frequent basis. This shift in format requires accelerated set-ups to maintain flexibility, to meet customer demands, and to remain competitive.
SMED allows you to make the necessary reductions in changeover time to achieve a just-in-time pace. The practices under this system achieve machine changeover in less than 10 minutes (single digit minutes) thus reducing the time during which production is down. The SMED approach does not only just reduce changeover times but also the overall labor involved.
The goals of SMED are:
Reduction in inventory
Reduced changeover time
More efficient changeover process
Flexibility for reduced batch/lot size
Improve flexibility in equipment usage
Reduce impact and downtime on equipment
Meet customer demand
SMED Process
SMED involves certain steps, with a basic overview as follow:
Elimination of Non-Essentials: Observe and record the areas where change outs are required, then eliminate all non-essential activities where possible, especially duplication. By eliminating non-essential activities it is possible to speed things up and reduce waste.
External Set-up: Get all the materials and supplies to be used in place so that they are available when required. Some things to consider for this include: color code all items needed, create checklists and develop and maintain uniform standards and procedures
Internal Set-up: Replace complex tools where possible with more simple equipment to prevent unnecessary waste. Use functional jigs and fixtures, levered or one-turn fasteners, preset guides, pins and notches. Remember the goal is to work efficiently but still but also effectively.
Measure: The SMED approach entails change, but to know if you’re on the right track it is vital to measure business performance every time. It is a successful way of knowing if improvements are being made or not. Based on the results obtained, corrective or proactive measures can be taken. Consider the time lost/wasted as the benchmarks you will need to improve upon.
Benefits of Equipment Maintenance
The SMED system also requires proper maintenance of tools and equipment. When equipment is well looked after, it is more reliable. It will result in production efficiencies and lower costs due to fewer breakdowns and equipment downtimes. Also, with an effective maintenance program, equipment required will be available as and when necessary reducing wasted time and high costs due to idle equipment and staff.
It is also imperative that molds are stored properly to ensure optimal performance and longevity. Instead of leaving it on the floor or on pallets where it can sustain damage, it is best to store molds in a designated storage area or if possible on shelving or racks. Furthermore, it is best to use rust preventatives and grease that require little or no pre-production cleaning for start-up.
Many companies treat mold maintenance as an after thought, and have yet to explore how new products (like the Nanoplas line of mold maintenance products) can have a significant impact on their set-up and speed to press times. These gains in production efficiencies when combined with an approach like SMED can have a real impact on the bottom line.
To learn more about how the integrated family of Nanoplas products can help reduce scrap, increase production efficiencies and save time for your injection molding operation, contact us today!
In some industries, the rise of machines more capable of performing complex tasks is taking the place of human workers. Here’s an article from BetaBoston claiming that in the manufacturing industry things are different…
“It appears the manufacturing industry may be a special case, in which automation and artificial intelligence can actually protect jobs rather than replace them.”
How is this?
The robots are able to accomplish automated tasks that help keep costs down and help American companies win bids against Chinese or other overseas low-cost manufacturing companies. So far, this has worked with the companies who tried it, and none of them have laid off workers, giving these robot manufacturer’s claims more and more validity.
“In today’s world, the green movement is more important than ever. No matter what the industry, it’s a company’s duty to make changes and choices that support the environment.”
Here’s a great article from The Rodon Group about working with injection molders that are environmentally friendly in their practice. The article lists some of the things you should look for in a company including lead manufacturing processes such as waste minimizing technology and landfill-free facilities.
“There is no better cost to eliminate than the cost of poor quality.”
Here’s a great article from Industry Week that outlines 5 steps to improving manufacturing quality. Some of them are organizational tips; others stress the importance of collaboration and a team mindset and culture. They’re all important points for any manufacturer.
“In order to best eliminate these wastes, a strategic approach to quality improvement is essential.”
Here’s a quick article that outlines the benefits of the manufacturing mindset that is changing the way manufacturing is being done. The implementation of lean manufacturing through trying to make value flow at the pull of the customer prevents and eliminates the 7 categories of waste in your processes: Transport, Inventory, Motion, Waiting, Over-processing, Overproduction, and Defects.
Learn more about lean manufacturing by reading the full article HERE.
Many complex and critical parts of machinery are difficult to make since they have challenging shapes and sizes. Furthermore, some injection molding companies do not always have the expertise, knowledge and equipment to make these complex parts. That’s why, when choosing your injection molder, it’s necessary to find out whether the molder has the specialization to mold complex parts using injection molding.
The Pathway to Molding Complex Parts
Molding complex parts of varying shapes and sizes and using a variety of materials is an art as well as a science. The molder should have in-depth knowledge of different materials and a thorough understanding of the injection molding equipment. This will ensure the end customer gets a high performing and precision part.
The Process of Molding Complex Parts
The process of making complex parts with injection molding depends on using scientific methods, the latest analytical tools and process technologies to ensure the resultant parts offer high quality performance. Usually, the process is divided into four stages. These stages are as follows:
Designing the complex part
Selecting the right material
Designing the mold
Process control
Designing the Part: It’s important that the part is accurately and precisely designed, taking into consideration its end use. Designing the part allows for changes and adjustments during the initial stages and this helps reduce the overall cost of making the part as well as the timeline to make the part. During the designing phase, more emphasis is laid on maximizing the design to ensure it can be manufactured seamlessly and fulfill its end-use requirement.
Material Selection: This perhaps is one of the most important steps in the entire process of injection molding. When it comes to complex materials, often multiple materials are required. Hence, there is a need to select polymers that are compatible with one another as well as ones that can bond permanently and offer faultless performance.
Mold Designing: During the mold designing process, it is important and critical to keep a close watch on the mold cavity parameters, such as temperature and pressure. This is the stage where changes and adjustments are made in real-time to ensure the resultant complex parts are consistent in quality and performance. The mold design is dependent to a certain extent on the end-use of the part and the materials being used to make the part.
Process Control: Based on the design of the product and end-use, the appropriate injection molding technologies are used. There is a wide range of complex molding process, such as overmolding, multi-shot molding and insert molding, that can be used based on design and end-use. For instance, if there is a need to make the part appear attractive and stylish and give it a good grip, overmolding is often used during the injection molding process. This helps to reduce vibrations, improves resistance to UV rays, and it also enhances electrical insulation, thereby increasing the longevity of the part.
Injection molding can be customized to make any type of part, complex or otherwise. Each part is made using a set of production processes that help to hasten the production and molding of the part while maximizing its performance and quality.
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How SMED and Mold Maintenance Work Together
